Composite Materials having a Surface Texture for Absorbing Liquid

ABSTRACT

Composite materials of this invention include an absorbent layer and a non-absorbent layer, the absorbent layer having a textured surface for absorbing and trapping liquids, for example, oil, grease, or water, and the non-absorbent layer having an oleophobic surface that acts as an oil and grease specific liquid barrier. In one example, the surface texture includes a system of ridges and valleys that enhance the composite materials&#39; ability to absorb and hold liquids. The material further includes one or more lamination layers. The lamination layer acts as a general liquid barrier between the absorbent layer and non-absorbent layer. This additional liquid barrier enhances the liquid repelling effect of the non-absorbent layer to more effectively trap liquids in the absorbent layer, thereby preventing liquids from seeping through the material onto an external surface.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. patent application Ser. No.15/611,738, filed Jun. 1, 2017, and entitled “Composite Materials forFood Contact Applications” which is continuation-in-part of U.S. patentapplication Ser. No. 13/626,811, filed Sep. 5, 2012, and entitled“Disposable Pizza-Blotting Composite and Box”, the contents of which areexpressly incorporated herein in their entirety.

TECHNICAL FIELD

In general, the present disclosure relates to composite materials. Inparticular, composite materials that absorb and trap liquids aredescribed herein.

BACKGROUND

Many people enjoy “take-out” food as a convenient and economical meal.Many of these foods are messy to eat including fries, pizza, nachos,burritos, tacos, fried rice, stir fry, macaroni and cheese, pasta, friednoodles, fried chicken, hot dogs, burgers, bbq, popcorn, cookies andother baked goods. Liquids including oil, grease, and other organicliquids and water and other polar liquids saturate many take out entreesand drip from conventional food packaging to ruin clothing, upholstery,and the experience of eating.

Despite the mess, many types of take out food are increasing inpopularity, for example, pizza. In addition to the mess of pizza grease,high amounts fat, cholesterol, and sodium make eating pizza unhealthy.Accordingly, there exists a long felt, but unresolved need for acomposite material to make food packing that removes fats, grease, oils,and other excess nutrients from the surface of meat, cheese, and dough.

Conventional methods of making take out food healthier include usingnapkins and other paper products to blot excess oil and grease from afood surface before eating. This approach, however, is ineffectivebecause the oil and grease bleeds through the napkin and transfers tothe hands of the consumer, thus requiring the use of additional napkins.It is also inefficient because conventional paper products are notoptimized to absorb and trap grease. Therefore, others have failed touse conventional methods and materials to minimize the adverse healtheffects of eating take out foods while also improving the eatingexperience.

Excess waste is another problem associated with conventional materialsused in food contact applications, for example food packaging. Althoughcatchy, colorful, and excessive packaging helps drive sales, it createsunnecessary waste. Worse, many conventional food packaging assembliesare layered and comprise multiple materials, for example, food packagingthat comprises a plastic layer enclosed within another paper box outercontainer. Layering packaging with multiple materials is excessive andmakes food packaging more difficult to recycle because of sorting.Accordingly, others have failed to create materials fit for food contactapplications that form a single composite material and reduce overallwaste.

According to the federal Environmental Protection Agency (EPA), foodcontainers and packaging make up over 23% of all material reachinglandfills. To encourage less waste production, the EPA asks businesses,communities, and households to eliminate waste before reusing orrecycling. Waste reduction is important component of a sustainablesociety because it reduces the amount of raw materials extracted in themanufacture of a product and reduces the water, energy, oil and otherresources need to manufacture, transport, sell and consume the product.

Due to wasteful and ineffective conventional materials for food contactapplications, food packaging comprises most of the litter polluting USroadways, waterways, and beaches. Conventional materials, for example,plastic food packaging are non-compostable, non-biodegradable, and donot readily disintegrate. Instead discarded food packaging accumulatesin the environment harming wildlife and disrupting ocean dependentindustries including shipping, fishing, tourism, and other oceandependent industries. Therefore, wasteful and ineffective food packagingmaterials is a recognized problem.

Conventional materials for food contact applications also containsubstances that are harmful to human health. Expanded Polystyrene (EPS,often called STYROFOAM, a product manufactured by DOW CHEMICAL COMPANY)is one harmful material often found in food packaging materialsincluding, for example, takeout containers, drink cups, and plates. EPSis made from non-biodegradable petroleum-based polymer materials anddoes not break down. Instead, in the presence of sunlight, itphotodegrades into small pieces. Additionally, reach shows harmfulchemicals leach from EPS containers that contact hot, greasy, or acidicfood. All discarded EPS either takes us space in a landfill or ends uppolluting land and waterways because it does not naturally compost orbiodegrade. In the ocean, EPS breakdowns into its monomer styrene, ahuman carcinogen. Accordingly there exists a long felt, but unresolvedneed for materials fit for food packaging applications that do notcontain EPS.

Many communities have passed laws banning the use of EPS. In California,65 ordinances have passed either prohibiting restaurants from using EPSor requiring the use of compostable or recyclable containers. Maine bansthe use of EPS for serving individual portions of food or a beverage ata facility or function of the State or of a political subdivision unlesscontainers are recycled. Additionally, communities in Massachusetts, NewJersey, New York, Oregon, Texas, Washington and Washington D.C. have allbanned EPS, in food service applications. Lastly, in 2015, New York Citypassed an ordinance banning all types of ESP food waste and foampackaging peanuts. Accordingly, the presence of EPS in food contactapplications is a recognized problem.

Perfluorinated chemicals or PFCs are another class of harmful materialscommonly found in conventional materials used in food contactapplication. The adverse human health impacts of PFCs have been welldocumented over the last decade. Research shows that evenextraordinarily small doses of Teflon, PFOA, and other PFCs can beharmful to human health. For example, a 2006, report from the U. S.Environmental Protection Agency (EPA) Science Advisory Board said PFOAis “likely to be carcinogenic to humans.” Additionally, in 2012, anindependent science panel funded by DuPont reported “probable links”between PFOA exposure and testicular and kidney cancer, thyroid disease,pregnancy-induced hypertension and preeclampsia, ulcerative colitis andhigh cholesterol. More recent research finds that even the smallestdoses of PFOA, PFOS, and other PFCs are harmful, because most Americansalready have elevated levels of perfluorinated chemicals in their bloodstream due to prolonged exposure. Accordingly, there exists a long felt,but unresolved need for materials fit for food contact applications thatdo not contain PFCs.

Despite the well documented health hazards of PFCs, companies such asDUPONT and 3M have not always been forth coming about the risks ofperfluorinated chemicals. In 2001, 3M stopped producing its Scotchgardchemical after admitting to the EPA it withheld decades of damninginternal studies on PFCs' health hazards. Additionally, court documentsfrom a West Virginia class action case against DuPont revealed thecompany had also covered up unfavorable internal studies. In 2006, theEPA fined DuPont a then record $16.5 million and the company agreed tophase out PFOA by 2015. Accordingly, others have failed to creatematerials fit for food contact applications that do not contain PFCs.

In an effort to protect consumers, FDA banned PFOA from food packaging.Other PFC substances, for example, TEFLON (perfluorooctanoic acid orPFOA) were phased out of food contact applications after being linked tocancer and reproductive and developmental harm. The agency, however,continues to allow the use of other PFCs with slightly differentchemical structures in food packaging applications. The FDA has approved20 types of PFCs for coating paper and paperboard used to serve food.Despite regulatory approval, concerns about the health impacts of PFCspersist due to insufficient testing, particularly of new PFC compounds.DuPont even filed documents with the EPA, reporting GenX, one of theirnext-generation PFC chemicals used to coat food packaging, could pose a“substantial risk of injury,” including cancerous tumors in the pancreasand testicles, liver damage, kidney disease and reproductive harm.

Other companies have tried to avoid materials containing PFCs. BURGERKING, for example, stopped using paper coated with fluorinated chemicalsin 2002. MCDONALD'S also pledged to move away from PFOA coatings. On theproduction side, the manufacture of PFOA by DUPONT and seven othercompanies in the U.S. ended ahead of schedule in 2011. Additionally, theFDA officially banned the use of three PFOA-based chemicals in foodpackaging in January 2016. The FDA also added two new PFOS-basedchemicals to its ban in November 2016 after receiving a petition from 3Mindicating that production ended almost 15 years earlier. Therefore, thepresence of PFCs in materials used for food contact applications is arecognized problem.

Despite the FDA's ban, tests indicate many conventional materials usedin food contact applications, for example, food packaging used by somefast food outlets, are still coated with grease resistant PFOA, PFOS, orrelated chemicals. Alternatively, many chains are using papers coatedwith next-generation PFCs hoping they are “safer”. In 2014 and 2015,tests undertaken by non-profit research organizations, along withfederal and state regulatory, and academic institutions studied wrappersfor sandwiches and burritos, bags for fried foods, chips, and pastries,pizza and chicken boxes, and other paper and paperboard items used toserve food from twenty seven fast food chains and other restaurants inthe U.S. The study revealed that of the three hundred twenty sevensamples collected between 2014 and 2015 from fast food outlets inBoston, San Francisco, Seattle, Wash., D.C., and Grand Rapids (MI), 40percent tested positive for fluorine, an indicator of PFCs. Furthertests on smaller numbers of samples found the overwhelming majority offood packaging contains PFCs. More specifically some samples were foundto have traces of PFOA, the former Teflon chemical. In these studies,PFCs showed up in food packaging used at many of the most popular andwell-known fast food restaurants, including. ARBY'S, BURGER KING,CHIC-FIL-A, DAIRY QUEEN, DUNKIN DONUTS, JIMMY JOHNS, PANERA, STARBUCKS,QUIZNO'S, and TACO BELL. Accordingly, others have failed to creatematerials for food contact applications that do not contain PFCs.

PFC-based coatings on food packaging materials present a serious healthrisk because the hot, fatty foods served in PFC packaging soak up thechemicals in contact with the food. By eating food served in PFCpackaging, consumers often consume PFCs and other chemicals. A 2008 FDAstudy found that “fluorochemical paper additives do migrate to foodduring package use,” and oil and grease “can significantly enhancemigration of a fluorochemical from paper.” Additionally, a 2009 EPAstudy identified food contact paper as a key pathway for PFCs to enterthe body. Therefore, there exists a long felt, but unresolved need formaterials for food contact applications that contain no PFCs.

Oil and grease contamination is another problem associated withconventional food preparation techniques that use conventional materialsfor food contact applications including cooking. Contamination from oiland grease is one of the biggest threats to clean municipal water in theUnited States. To maintain clean water, the National PretreatmentProgram (NPP) implements the Clean Water Act requirements to controlpollution in Publically Owned Treatment Works (POTWs). As part of theNPP, the EPA requires State and local governments to control pollutantsthat complicate POTW treatment processes or contaminate POTW sewagesludge. These requirements typically mandate eliminating the dischargeof Fats, Oils, and Grease (FOG) from food service establishments (FSE).More specifically, the NPP regulations prohibit “solid or viscouspollutants in amounts which will cause obstruction” in the POTW and itscollection system. The EPA's Report to Congress on combined seweroverflows (CSOs) and sanitary sewer overflows (SSOs) identified that“grease from restaurants, homes, and industrial sources are the mostcommon cause (47%) of reported blockages”. FOG is a big problem formunicipal water infrastructure because it “solidifies, reducesconveyance capacity, and blocks flow.” The annual production ofcollected grease trap waste and uncollected grease entering sewagetreatment plants can be significant and ranges from 800 to 17,000pounds/year per restaurant. Accordingly, FOG contamination of municipalwater is a recognized problem.

In response to the overwhelming number of FOG caused blockagesidentified in CSO/SSO Report to Congress, a growing number of controlauthorities are establishing and enforcing more FOG regulatory measuresto control FOG discharge by FSEs. Federal, State, and local governmentsare employing regulatory methods to encourage FSEs to adopt bestmanagement practices. These regulatory methods include frequentinspections, periodic grease pumping, stiff penalties, and even criminalcitations for violators, along with ‘strong waste’ monthly surchargesadded to restaurant sewer bills. Reported surcharges range from $100 toas high as $700 or more. In light of this harsh regulatory environment,FOG discharge is a serious problem for any restaurant that deep friesfood or prepares food containing high concentrations of FOG.Accordingly, there is long felt, but unresolved need for a material usedin food contact applications, including cooking, that absorbs FOG andprevents FOG contaminates from reaching the clean water supply.

Using conventional materials in food contact applications alsocontaminations recycling and composting streams. Recycling is animportant component of a sustainable system of waste disposal with somestate and local recycling operations diverting as much as 25%-90%+ ofwaste away from landfills. Food packaging materials, for example, pizzadelivery boxes, made from recyclable materials, including corrugatedcardboard, become contaminated when fats, oils, and grease from cookedmeat, cheese, and dough are absorbed into the material. The oilysubstances are incompatible with the water based process of making pulpfrom recycled paper and thereby cause otherwise recyclable foodpackaging materials to become landfill waste. Due to the costly problemsassociated with grease contamination of pulp including paper plantshutdowns for equipment maintenance and cleaning, the vast majority offood packaging is not recycled. Accordingly, FOG contamination in therecycling stream is a recognized problem and there exists a long felt,but unresolved need for a composite material fit for food contactapplications that protects recyclable food packaging materials from FOG.

It is estimated that up to 20% of all municipal solid waste in the US isfood waste. Composting currently offers the best opportunity to divertfood waste away from landfills because alternatives including animalfeed and bio-digestion are high regulated and relatively unproven atscale. Unfortunately, as with recycling, contamination is the largestforce undermining current composting efforts. Incorporating FOG andother materials that do not break down in the composting processincreases costs and decreases the quality of the end product, humus, theorganic component of soil. Additionally, food packaging contaminates inthe composting stream, require many commercial composting operations toinvest in state-of-the-art depackaging and screening equipment beforethey can accept food waste. Accordingly, there exists a long felt, butunresolved need for a composite material used in food contactapplications that is compostable in large-scale composting operations.

Regulations have been in enacted in many jurisdictions to encourage foodwaste diversion through composting. For example, state governments inConnecticut, Massachusetts and Vermont have laws prohibiting landfilldisposal of food waste from large commercial food waste generators.Similarly, municipal governments in New York City and Austin, Tex. haveprograms for diverting large-scale food scraps from hotels, hospitals,and other large generators. To divert residential waste, thesejurisdictions offer curbside organic composting. Other regulatoryschemes require large food waste generators, such as restaurants andgrocery stores, to separate and divert food waste from trash. Forexample, San Francisco and Seattle both have mandatory requirements forfood waste diversion for all generators including residential andcommercial establishments. An alternative approach incentivizes wastediversion. In San Diego and Charleston County, South Carolina,separating food waste from other trash significantly reduces the tippingfee for waste collection.

Despite increased regulation and the environmental and practicalbenefits of composting food waste including less crowded landfills,lower overall trash production, and cheaper trash disposal, only about10% of commercial establishments currently process food waste. BioCycleMagazine, the premier resource for compost and organics news, reportedthat of the approximately 5,000 compost operations across the country,only about 500 of them are accepting food waste. The greatestopportunity for expansion of food waste composting, therefore, lies inlarge-scale operations. Accordingly, others have failed to develop andimplement compostable materials for food contact applications in orderto establish composting as an effective technique for diverting foodwaste.

Greenwashing and other methods of disseminating disinformation about aproduct to present an environmentally responsible public image is acommon and effective form of false advertising associated withenvironmentally friendly products. Clear testable standards can reducethe impact of greenwashing by making composting practices moretransparent and easier to understand. There are many words to describeproducts that break down under various conditions, for example,compostable, biodegradable, degradable, and photogradable. As morematerials for food contact applications become marketed as recyclable,biodegradable, compostable, bio-digestible, and/or photogradable,standards for these materials must be clear and easily enforced to avoidcontamination across the spectrum of disposal streams. Accordingly,there is a need for a compostable food packaging material that meetsinternationally accepted composting standards, for example, Europe's EN13432 found in European Directive 94/62/EC, the American Society forTesting and Materials D6868, and the Australian Standard AS4736-2006.

Obesity stemming from overconsumption of take out foods and other foodshigh in fat, cholesterol, and sodium is one of the biggest public healthproblems in the United States. According to the Center for DiseaseControl, more than one-third of adults (36.5%) and 17% of youth in theUnited States are obese. The World Health Organization (WHO) reportsthat obesity is associated with a “greatly increased risk” of diabetes,gall bladder disease, hypertension, dyslipidemia, insulin resistance,breathlessness, and sleep apnea; a “moderately increased risk” ofcoronary heart diseases, osteoarthritis, hyperuricemia, and gout; and“slightly increased risk” of cancers, reproductive hormoneabnormalities, polycystic ovary syndrome, impaired fertility, low backpain, increased anesthetic risk, and fetal defects as a result ofmaternal obesity. According to a WHO report obesity is on the rise inthe US and worldwide with the number of obese adults now estimated to beover 300 million. This represents a 33% increase from 200 million in1995.

Unhealthy dietary habits leading to overconsumption of fat, cholesterol,and sodium is a leading cause of the growing global obesity epidemic.According to studies conducted by the National Institute of Health(NIH), overconsumption of food rich in fat leads to weight gain becausefat has low satiety properties and high caloric density. Epidemiologicalevidence uncovered by the NIH suggests a high-fat diet promotes thedevelopment of obesity and indicates a direct relationship between theamount of dietary fat and the degree of obesity. The American Journal ofClinical Nutrition has also published evidence indicating a causalrelationship between dietary fat intake and obesity. This work statesthere is ample research from animal and clinical studies, fromcontrolled trials, and from epidemiologic and ecologic analyses toprovide strong evidence that dietary fat plays a leading role in thedevelopment and treatment of obesity. Accordingly, a high-fat dietresulting from overconsumption of take out foods is a well recognizedproblem.

Results from 28 clinical trials studying the effect of reducing theamount of energy from fat in the diet further confirm lowering dietaryfat is a leading treatment for obesity. Many publications including arecent article in the journal of the American Dietetic Association Datademonstrate the positive impact absorbing unhealthy nutrients from takeout foods has on dietary fat. The paper includes data, complied by IowaState University from the U. S. Department of Agriculture's NutrientDatabase, suggesting fat from meat contributes a significant portion ofthe calories and fat in many unhealthy diets. Iowa State University'sDr. Garden-Robinson notes that draining fat from ground beef and othermeats after cooking significantly reduces fat and calorie content.Therefore, there is a long felt, but unresolved need for materials usedin food contact applications that absorb FOG from food surfaces.

In addition to high dietary fat, elevated levels of dietary sodium cancause serious health concerns. Harvard University's School of PublicHealth reports kidneys in most people with high sodium diets havetrouble processing excess sodium in the bloodstream. As unfilteredsodium accumulates, the body holds onto excess water to dilute thesodium. This increases the amount of fluid surrounding cells and thevolume of blood in the bloodstream. Increased blood volume puts morepressure on blood vessels while making it more difficult for the heartto circulate blood. Over time, the extra work and pressure stiffensblood vessels and accelerates heart aging. Deteriorating blood vesselsand cardiac tissue, in turn, leads to high blood pressure, heart attack,stroke, and heart failure. As the leading cause of heart disease, highblood pressure is a serious medical condition. It accounts fortwo-thirds of all strokes and half of all cases of cardiac disease.There is also evidence suggesting that high amounts of dietary saltdamages the heart, aorta, and kidneys independent of increasing bloodpressure and volume.

A recent study in Archives of Internal Medicine provides more evidencethat high salt diets have negative effects on health. In this study,people with the highest sodium intakes had a 20 percent higher risk ofdeath from any cause than people with the lowest sodium intakes. Besidescontributing to high blood pressure, consuming high amounts of sodiumcan also lead to stroke, heart disease, and heart failure. Research alsoshows that reducing sodium lowers cardiovascular disease and death ratesover the long term. Research also shows that higher intake of salt,sodium, or salty foods is linked to an increase in stomach cancer. TheWorld Cancer Research Fund and American Institute for Cancer Researchconcluded that salt, as well as salted and salty foods, are a “probablecause of stomach cancer.” A diet high in sodium is also linked toosteoporosis, the bone-thinning disease. The amount of calcium that yourbody loses via urination increases with the amount of salt you eat. Ifcalcium is in short supply in the blood, it can be leached out of thebones. Some studies have shown that reducing salt intake causes apositive calcium balance, suggesting that reducing salt intake couldslow the loss of calcium from bone that occurs with aging. Accordingly,excess sodium in the bloodstream resulting from elevated dietary sodiumis a well recognized problem. Advanced food packaging materials thatmake food healthier by absorbing unhealthy substances are one solutionto this problem. Therefore, there exists a long felt, but unresolvedneed for materials used in food contact applications that absorb sodiumfrom food surfaces.

In addition to elevated levels of FOG and sodium, high dietarycholesterol can cause serious health problems. There are two types ofcholesterol, one considered “good” and the other considered “bad”.High-density lipoprotein (HDL), or “good,” cholesterol picks up excesscholesterol and takes it back to ones liver. Low-density lipoprotein(LDL), or “bad,” cholesterol transports cholesterol particles throughoutyour body. LDL cholesterol builds up in the walls of your arteries,making them hard and narrow. Many factors determine a person'scholesterol levels including genetic makeup, inactivity, obesity, anunhealthy diet, diabetes and smoking.

According to the Centers for Disease Control and Prevention, 73.5million adults (31.7%) in the United States have high low-densitylipoprotein (LDL), or “bad,” cholesterol. Fewer than 1 out of every 3adults (29.5%) with high LDL cholesterol has the condition under controland less than half (48.1%) of adults with high LDL cholesterol aregetting treatment to lower their levels. People with high totalcholesterol have approximately twice the risk for heart disease aspeople with ideal levels. Nearly 31 million adult Americans have a totalcholesterol level greater than 240 mg/dL.

According to the Mayo Clinic, high cholesterol can causeatherosclerosis, a dangerous accumulation of cholesterol and otherdeposits on the walls of your arteries. Once coronary arteries thatsupply the heart with blood become affected by cholesterol buildup,chest pain and other symptoms of coronary artery disease may occur. Thisbuildup often combines with calcium and other bioavailable substances toform plaques, which can tear or rupture arteries and other bloodvessels. After tearing, a blood clot often develops at theplaque-rupture site. This clot can block the flow of blood or breakingfree and plug an artery downstream. Such blockages are very dangerousbecause they frequently stop blood flow to part of the heart causingheart attacks. Similar conditions in the brain, lead to blocked bloodflow to neural tissue and stroke. Accordingly, cholesterol accumulationon artery walls resulting from elevated dietary fat and cholesterol is awell recognized problem.

Despite the well-documented danger of high fat, sodium, and cholesteroldiets, many unhealthy food options exist. These take out food optionsare staples of many diets because fresh food such as fruits andvegetables are less convenient, more expensive and less accessible.Since eliminating take out food is not a realistic option for manypeople, a multi-billion dollar pharmaceutical industry has beendeveloped to help people many the symptoms associated with maintainingan unhealthy diet. For example, many prescription drugs help lowercholesterol and treat other symptoms of obesity including diabetes, highblood pressure, and heart disease. Although many of these drugs aretemporarily effective there are often significant costs and potentialside effects associated with this path of treatment. Therefore, thereexists a long felt, but unresolved need for materials used in foodcontact applications that absorb fat, sodium, and cholesterol from foodsurfaces.

SUMMARY OF INVENTION

The invention included herein comprises a composite material for foodcontact applications. The composite material includes an absorbent layerand a non-absorbent layer, the absorbent layer having an oleophilicsurface for absorbing and trapping liquids, for example, oil, grease, orwater, and the non-absorbent layer having an oleophobic surface thatacts as an oil and grease specific liquid barrier. The material furtherincludes one or more lamination layers. The lamination layer acts as ageneral liquid barrier between the absorbent layer and non-absorbentlayer. This additional liquid barriers enhances the liquid repellingeffect of the non-absorbent layer to more effectively trap liquids inthe absorbent layer, thereby preventing liquids from seeping through thematerial onto an external surface.

The composite material may be used as a food packaging material thatabsorbs fat, calories, cholesterol, sodium, and other substances fromthe surface of greasy take out foods. Food packaging made from thematerial also prevents contamination in the recycling stream bypreventing FOG and other liquids absorbed from a food surface fromcontacting food packaging assembles made from recyclable materials, forexample, corrugated cardboard. The material is also flourine-free, EPSfree, non-biotoxic, and safe for food contact applications. As usedherein, “fluorine free” refers to materials that are composed of rawmaterials and ingredients that are free from perfluorooctanoic acid(PFOA, CAS 335-67-1), ammonium perfluorooctanoate (CAS 3825-26-1),perfluorooctane sulfuic acid (PFOS, CAS 1763-23-1), potassiumperfluorooactane sulfonate (CAS 2795-39-3), ammonium perfluorooactanesulfonate (CAS 29081-56-9), lithium perfluorooctane sulfonate (CAS29457-72-5), diethanolamine (DEA) salt (CAS 70225-39-5),perfluorooctanesulfonyl fluoride (CAS 307-35-7), perfluorinatedcarboxyilic acids (PFCAs), for example, perfluorononanoic acid (CAS375-95-1), perfluorodecanoic acid (CAS 335-76-2), perfluoroundecanoicacid (CAS 4234-23-5), perfluoroundecanoic acid (CAS 307-55-1),perfluorododecanoic acid (CAS 307-55-1), perfluorotridecanoic acid (CAS72629-94-8), perfluorotetradecanoic acid (CAS 376-06-7),hexacosafluoro-13-(trifluoromethyl)tetradecanoic acid (CAS 18024-09-4),perfluorohexadecanoic acid (CAS 67905-19-5), perfluorooctadecanoic acid(CAS 16517-11-6), and perchlorate (CAS 14797-73-0). As used herein,“non-bioxtoxic” refers to materials that are composed of raw materialsand ingredients that are free from heavy metals including Arsenic,Barium, Cadmium, Chromium, Lead, Mercury, Selenium, and Silver, andsubstances listed as carcinogens by the Occupational Safety and HeathAdministration (OSHA). As used herein, “safe for food contactapplications” refers to materials that comply with the Federal Food andDrug Cosmetic Act under applicable sections and provisions of Title21CFR including parts 175: Adhesives and Components of Coatings, 176:Indirect Food Additives: Paper and Paperboard Components, and 178:Adjuvants and Production Aids or the FCN Program. As used herein, “foodcontact applications” refers to producing, manufacturing, packaging,processing, preparing, treating, cooking, packing, transporting, orholding foods.

In at least one example, the material is 100% compostable according tointernational composting standards. As used herein, “degradable” refersto materials that disintegrate over a number of years, but do not have adefined amount of time or conditions under which they degrade. As usedherein, “biodegradable” refers to materials that break down throughprocessing by a naturally-occurring organism, for example, a bacteria,fungi, or algae. Biodegradable does not require the material to breakdown in a certain period of time, nor under the conditions found in thecomposting process. Degradable and biodegradable materials do not meetall composting standards therefore contaminate the composting stream.Therefore, it is important for food service establishments and consumersto easily recognize the difference between degradable and biodegradablematerials and compostable materials in order to avoid introducingcontaminants into the compost stream. As used herein, “compostable”refers to materials that contain no heavy metal content, disintegrate inless than 84 days and completely biodegrade in less than 180 days. TheEuropean Standardization Committee's (CEN) EN 13432 lays down criteriafor what can or cannot be described as compostable and what can becalled biodegradable. The US Standards ASTM D6400-99 and ASTM D6868-11sets out similar standards. European Standard EN 13432 is the basis ofthe International Standards Organization (ISO) Standard ISO14855. Thesestandards ensure compostable materials break down in industrialcomposting conditions. Materials that meet either the European or USStandard will break down effectively in virtually every commercialcomposting system. The Australian Standard AS4736-2006 is closely basedon EN 13432, with the exception of a worm eco-toxicity test not requiredby the other standards. International composing standards requirecompostable materials to meet the following criteria:

“Biodegradability”—measured by metabolic conversion of the material tocarbon dioxide to at least 90% in less than six months. (90% is used toaccount for sampling error, not to allow for non-biodegradablematerial).

“Disintegrability”—there should be fragmentation below a certain sizewith no visible contamination (screened at 2 mm after 180 days with lessthan 10% original mass)

Absence of negative effects on the final compost using a plant grow testand physical/chemical analyses

Chemical/physical parameters identical to compost without the testmaterials after degradation—pH, salinity, volatile solids, Nitrogen,Phosphorous, Magnesium and Potassium.

Composite materials of this invention are configured for use as foodpackaging and cooking materials in restaurants, homes, fast-foodkitchens, food trucks, event concessions, and other food services. Whenused as cooking materials, for example, cookware liners, the compositematerial helps FSEs keep FOG discharge within the EPA reported range oflocal limits (50 mg/L to 450 mg/L). By soaking up FOG from foodscontaining meats, dairy, and other FOG producing ingredients before,during, and after the cooking process, the material can be used by FSEto reduce FOG discharge and eliminate the threat of FOG caused sewerblockages and overflows. In one example, food packaging made from thecomposite material soaks up FOG while the food is in storage. In anotherexample, baking sheet covers and other cookware liners made from thematerial absorb grease as it is secreted during the cooking process. Inanother preferred embodiment, the composite material is applied tocooked food either directly or through integrations with an existingfood packaging assembly such as pizza boxes, chip and popcorn bags, andsandwich wrappers to absorb grease after cooking. Using the compositematerial in all food contact applications, FSEs preparing greasy takeout foods such as pizza, hamburgers, tater tots and French fries, corndogs, doughnuts, or biscuits can eliminate FOG discharge and dispose FOGin a sustainable way.

The composite material may also be incorporated into conventional foodpackaging assembles to reduce FOG contamination of recycling andcomposting streams. Once FOG and other liquids are absorbed in theabsorbent layer, the lamination layer and non-absorbent layers act asliquid barriers to prevent FOG from seeping through the compositematerial and into food packaging. These structures for absorbing andtrapping grease allow the composite material to protect recyclable foodpackaging materials, for example, pizza boxes and take out foodcontainers, from excess FOG in greasy take out foods. Accordingly,communities, food services, and other organizations seeking to divertwaste away from landfills through recycling can use to compositematerial to absorb excess FOG and prevent FOG contamination ofrecyclable food packaging materials.

Similarly, compostable embodiments of the composite material makes foodwaste diversion through composting easier by eliminating the need todisaggregate food packaging from food waste. In at least one example,the composite material is incorporated into a compostable food packagingassembly that completely breaks down under industrial compostingconditions. The compostable characteristics of the composite materialhave been proven using laboratory precision and perfected under actualconditions through test kitchen and actual biodegradation experiments.The composite material contains no volatile matter or heavy metals andis fluorine free, non-biotoxic, and safe for food contact applications.The material also has a flash point greater than 400° F. and is safe forhigh temperature cooking applications.

Embodiments of the composite material described herein, may have theircharacteristics and properties certified by at least one of federal,state, and local governments, environmental organizations, and otherthird parties. Environmental claims, including the composite material'sability to reduce chemical and FOG discharge and FSE water consumptionby alleviating dishwashing can be certified by the federal or state FDA.This certification distinguishes products made from the compositematerial from conventional products having a bigger FOG footprint inorder to educate the market and encourage firms to competitively developsustainable food packaging and cooking technologies. Specifically, theEPA may certify an embodiment of the composite material removes adefined amount or range of FOG from the water supply in accordance withthe Clean Water Act, the National Pretreatment Program (NPP), a FederalFinal Rule (FR), or a provision of the Code of Federal Regulations(CFR).

Additionally, governments and other third party organizations maypromulgate measures requiring FSEs, food packaging manufactures, andpaper companies to use or provide food packaging and cooking materialsthat reduce FOG discharge, for example, materials for food contactapplications made from the composite material described herein. Suchmeasures would promote better management of FOG discharge by FSEs thatfrequently cook meats, cheeses, baked goods, and other dishes withbutter, oil, or shortening.

Embodiments of the composite material may also be certified as a 100%compostable material by a third party organization. Many organizationscan certify the compostable properties of materials including governmentorganizations, for example, US state and federal agencies, including theFood and Drug Administration (FDA), Environmental Protection Agency(EPA), Federal Trade Commission (FTC), and the Department of Agriculture(USDA). Third party organizations such as the American Society forTesting and Materials (ASTM), the U.S. Composting Council (USCC)Certification Commission, the Biodegradable Products Institute (BPI),DIN CERTO (a German based company), Vincotte (a Belgium basedorganization), and Cedar Grove Composting (a Seattle, Wash. basedcompany).

To convey the compostable certification to consumers encountering thecomposite material in the marketplace, embodiments of the compositematerial may be marked with a logo or certification seal used bycertifying third party. The material can also be advertised and marketedas certified compostable through product packaging, press releases, andcommercials. Additionally, print and web publications such as PlanetNatural and BioCycle magazine can also publish a list of certifiedcompostable materials. Enforcement organizations such as the FTC, in theUS, are in place to verify products marked- and marketed as-certifiedcompostable meet the requirements of the certification. Currently, underthe FTC's current legal framework for combating unfair and deceptivetrade practices, if a product is tested and does not conform to thecertification, the product can be pulled from the market and the companyselling the product can face legal damages as well as bare the cost ofcreating and operating court ordered internal quality control measures.In addition to compostability, other properties of the compositematerial described herein may be certified by a government authority orthird party organization. These properties include the compositematerial's safety features, for example, the material's EPS, fluoride,and heavy metal free composition, the material's ability to reducerecycling stream and composting stream contamination, the material'sability to reduce water use by eliminating water needed to clean FOGfrom baking sheets, skillets, grills, and other cookware, and thematerial's ability to reduce water pollution by eliminating FOGdischarge from kitchen operations through absorbing FOG during thecooking process.

Embodiments of the composite material described herein make take outfood healthier by absorbing fat, sodium and cholesterol from the surfaceof take out food during preparation, transportation, and consumption. Bysoaking up excess nutrients from foods like meat, chicken, and friedfoods, for example, fried cheese, fried vegetables, French fries, onionrings, and corn dogs, the material provides a cost-effective andefficient way of reducing the negative health impacts of convenient takeout foods supplied by fast food restaurants, sit down restaurants, pubs,cafeterias, food trucks, and other food service operations at fairs,sporting events and festivals.

To convey the health effects and nutritional impact of the compositematerial, to consumers in the marketplace, the composite material may becertified by third party organizations including the federal FDA. In oneexample, the estimated amount of nutrients absorbed by the compositematerial is listed in the food's nutrition facts and nutritionallabeling in compliance with Chapter 7 of the federal FDA's food labelingguide in accordance with the Food, Drug, and Cosmetic Act. Health claimsrelating to the performance of embodiments of the composite materialincluding, for example, “heart healthy”, “lower fat”, “lower sodium”,“lower cholesterol”, “healthier food”, and corresponding logos may alsobe certified by a third party organization. In one example, the thirdparty organization is the federal FDA and the certification is grantedin compliance with Chapter 8 of the federal FDA's food labeling guide inaccordance with the Food, Drug, and Cosmetic Act. Health claims in thisexample may comply with the criteria set forth in a Federal Statute,Final Rule (FR), or provision of the Code of Federal Regulations (CFR),for example, 21CFR 101.9(k)(l), 101.14(c)-(d), and 21CFR 101.70.

In one example, the absorbent layer, the non-absorbent layer, and theone ore more lamination layers are joined to form a composite having abasis weight between 5 lb and 55 lb.

In one example, the composite material is dimensioned to cover all or asubstantial portion of a pizza's surface. In this example, the compositematerial may be fixed to a pizza box assembly with the non-absorbentlayer is secured to the interior top or bottom surface of the pizza box.In this embodiment, the oil and grease-blotting composite is positionedagainst the bottom surface of a pizza box to absorb oil and grease frombelow, leaving the upper surface of the pizza undisturbed andappetizing. It has been found that positioning the composite below thepizza in this position, with the absorbent side up, is highly effectivein extracting oil and grease from the pizza. Furthermore, thenon-absorbent layer at the bottom of the composite substantiallyprevents oil and grease from reaching the cardboard of the box,preserving the ability of the box to be recycled after use.Alternatively, oil and grease blotting composite layers may be placedboth above and below the pizza to extract oil and grease from bothdirections.

In a further embodiment, the non-absorbent layer may be an insulatingoil and grease resistant paper or metallic foil that reflects heat backtoward the pizza or other food item, thereby minimizing the dissipationof heat through the box.

More specifically, in an embodiment, the invention comprises adisposable food-blotting composite having an absorbent layer comprisinga physiologically safe cellulosic fibrous mat material with at least oneoleophilic surface; a flexible, non-absorbent layer underlying theabsorbent layer, the non-absorbent layer including a malleable polymericmaterial having at least one oleophobic surface: one or more flexiblelamination layers or coatings having at least one oleophobic surface,the flexible lamination layer for covering at least one surface of theabsorbent layer, the non-absorbent layer or both; wherein the absorbentlayer, the non-absorbent layer, and one or more lamination layers arejoined to one another to form a composite and wherein the composite isdimensioned to cover a substantial portion of a surface of an item offood with the absorbent layer configured to contact the item of food inuse.

Alternatively, a pizza box assembly according to the invention mayinclude a pizza box having a top and an inner receptacle covered by thetop; a pizza-blotting composite including an absorbent layer comprisinga physiologically safe material having at least one oleophilic surface;a flexible, non-absorbent layer containing a malleable material havingat least one oleophobic surface; and one or more flexible laminationlayers or coatings having at least one oleophobic surface, the flexiblelamination layer for covering at least one surface of the absorbentlayer, the non-absorbant layer or both; wherein the absorbent layer, thenon-absorbent layer, and the at least one lamination layer are joined toone another to form a composite and wherein the composite is dimensionedto cover a substantial portion of a surface of a pizza with theabsorbent layer facing the pizza in use, and wherein the non-absorbentlayer is attached to the bottom interior surface of the pizza box.

Alternatively, the composite material may be dimensioned to fit,converted into, or otherwise incorporated into other food packagingassemblies, for example, bags, napkins, trays, boxes, plates, bowls,cups, and other dishes, wrappers, sheets, liners, or cartoons. In analternative example, the composite material is used as an absorbent padfor cleaning up pet excrement, for example, urine and feces. Absorbentpads comprising the composite material may also be used for protectingmachinery, for example, car and motorcycle lifts, from oily substances,for example, motor oil, brake fluid, and engine lubricant. The compositematerial may also be used as a cleaning pad for cleaning oily substancesfrom tables, countertops, workstations, car interiors, and othersurfaces.

Composite materials used in these applications comprise an absorbentlayer that absorbs liquid and non-absorbent layer that forms a liquidbarrier to prevent liquid from seeping through the material. In theseexamples, composite materials may further include one or more laminationlayers that form additional liquid barriers and optionally, pockets ofspace between the absorbent and non-absorbent layers. The pockets can beconfigured to store a variety of materials including air, absorbedliquid, air freshener, additional cleaning chemicals, plant nutrients,seeds, fertilizer, pesticides, and herbicides.

Alternatively, the composite material may used as a seed mat. In thisexample, the seed mat comprises an absorbent layer that absorbs liquidand a non-absorbent layer that forms a liquid barrier to control thediffusion of irrigation water and/or fumigation gases. One or moreabsorbent or non-absorbent layers may be infused with seeds, fertilizer,plant nutrients, pesticides, and herbicides, and other substancesformulated to promote plant heath and growth. Optionally, the compositematerial may further include one or more lamination layers that formadditional liquid barriers and optionally, pockets of space between theabsorbent and non-absorbent layers. The pockets can be configured tostore a variety of materials including air, absorbed liquid, plantnutrients, seeds, fertilizer, pesticides, herbicides, and othersubstances formulated to promote plant health and growth.

In this example, the non-absorbent layer may be water resistant in orderto form a water barrier between the planted seeds and an externalsurface. This configuration seals water inside the material so that itcan be absorbed by the seeds for germination and plant growth. In thisexample, the composite material is compostable and safe for in-groundplanting. Enclosing seeds in the composite material removes the need forfarming plastic. It also prevents birds from eating the seeds and keepsplants warm in cold weather.

A method of the invention for extracting oil and grease from a food itemafter cooking includes i) obtaining a composite sheet having anabsorbent layer of a physiologically safe material having at least oneoleophilic surface; a flexible, non-absorbent layer underlying theabsorbent layer, the non-absorbent layer including a malleable materialhaving at least one oleophobic surface; and one or more flexiblelamination layers or coatings having at least one olephobic surface, theflexible lamination layer for covering at least one surface of theabsorbent layer, the non-absorbant layer or both; wherein the absorbentlayer, the non-absorbent layer, and the at least one lamination layerare joined to one another to form a composite and wherein the compositeis dimensioned to cover a substantial portion of a surface of an item offood with the absorbent layer facing the item of food; ii) placing thecomposite sheet above, below, or both above and below the item of foodafter it is cooked; and iii) discarding the composite sheet after oiland grease from the food item have been absorbed by the absorbent layer.

An alternative method of using the composite material to absorbnutrients from a food surface includes: i) obtain a take out food, ii)within 5 minutes of purchasing the food, insert the composite materialbetween the food packaging holding the food and at least one foodsurface so that the pad is between the food surface and the foodpackaging, iii) close the food packaging and weight 30 minutes, iv)remove the first composite material pad and apply a second pad to thefood surface by pressing down lightly to assure contact between the foodand the composite material, v) remove both pads after 2 minutes ofcontact by the second pad, vi) remove any loose material from the pads,and vii) dispose of the two pads of composite material.

The composite material may be configured to absorb grease from food,cooking oil, hydrocarbons, lubricants, or any other type of oilsubstance. The composite paper may also be configured to be recyclable,compostable, biodegradable, or otherwise configured for sustainable use.By combining the oil resistance necessary to prevent oil from spoilingotherwise recyclable food packaging with the disposal advantages ofpaper, for example, compostabilty and biodegradably, the composite paperdescribed herein offers a comprehensive and sustainable solution tocardboard spoilage.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and complete description of the present storage system isprovided herein with reference to the appended figures, in which:

FIG. 1 is a top plan view of one embodiment of a pizza liner comprisingof a composite material.

FIG. 2 is a cross-sectional view of the pizza liner of FIG. 1, as takenalong line II-II of FIG. 1.

FIG. 3 is a perspective view of a pizza box assembly containing thepizza liner of FIG. 1.

FIG. 4 is a perspective view of a sheet of a composite material. Oneaspect of the drawing includes a magnified view of the compositematerial.

FIG. 5 is a cross-sectional view of the sheet of composite material inFIG. 4, as taken along line 47 in FIG. 4.

FIG. 6 is a perspective view of a second embodiment of a pizza linercomprising a composite material.

FIG. 7 is a plan view of the pizza liner of FIG. 6.

FIG. 8 is a perspective view of a pizza box assembly containing thepizza liner of FIG. 6.

FIG. 9 is a perspective view of a third embodiment of a pizza linercomprising a composite material.

FIG. 10 is a plan view of the pizza liner of FIG. 9.

FIG. 11 is a perspective view of a pizza box assembly containing thepizza liner of FIG. 9.

FIG. 12 is a perspective view of a food bag assembly comprising acomposite material.

FIG. 13 is a perspective view of the food bag assembly of FIG. 12containing popcorn.

FIG. 14 is a plan view of the food bag assembly of FIG. 13.

FIG. 15 is a plan view of a baking sheet comprising a compositematerial. One aspect of the drawing includes baking pan having thebaking sheet disposed inside of the pan. Another aspect of the drawingincludes uncooked bacon on top of the baking sheet.

FIG. 16 is a plan view of the baking sheet of FIG. 15 after the baconhas been cooked on the sheet and removed from the baking pan. One aspectof the drawing includes a perspective view of one corner of the bakingsheet after the corner has been peeled back away from the baking pan.Another aspect of the drawing includes a plan view of a baking sheethaving a scored edge.

DETAILED DESCRIPTION

Reference is now made to the drawings for illustration of variousembodiments of the composite material and food packaging assemblies. Itshould be understood that the composite material may be made in anyshape, as needs dictate. The composite paper material may also beintegrated into any type of food packaging, for example, bags, trays,boxes, plates and other dishes, wrappers, foils, or cartons. Further, itshould be understood that the material described herein is equally wellsuited for absorbing oil from any greasy food including, for example,pizza, lasagna, fries, nachos, burritos, tacos, fried rice, stir fry,macaroni and cheese, pasta, fried noodles, fried chicken, hot dogs,burgers, bbq, bacon, sausage, and popcorn.

FIG. 4 is a sheet of composite material having an absorbent layer 40joined to a non-absorbent layer 49. The layers 40, 49 may be joined byany suitable means, including, but not limited to, gluing, laminating,seaming, embossing, quilting, and surface bonding. In laminatedembodiments, a degradable laminate may be applied to at least onesurface of the absorbent layer, non-absorbent layer, or both. Thelamination layer may be placed between the absorbent layer andnon-absorbent layer or added to an exterior surface of the absorbentlayer or non-absorbent layer. In one example, the absorbent layer 40 hasa surface texture 48 configured to enhance the layer's ability to absorbliquid. In some examples the surface texture 48 is optimized to absorbviscous, oleophilic liquids, for example, fats, oils, and grease. Inother examples, the surface texture 48 is optimized to absorb lowviscosity, oleophobic liquids, for example, water.

One aspect of FIG. 4 includes a magnified portion 42 of the compositematerial sheet. The magnified portion 42 provides a high resolution viewof a portion of the composite material sheet 41 to display oneembodiment of the surface texture 48 in greater detail. In this example,the surface texture 48 includes a system of ridges 43, 46, shown by darkblack lines, and valleys 44, 45, shown by the white space between thedark black lines. The ridges 43, 46 extend out from the surface of thecomposite material to form a network of narrow line segments elevatedfrom the main body of the absorbent layer 40.

When applied to a greasy food surface, the ridges 43, 46 contact thesurface before the main body of the absorbent layer. In thisorientation, the ridges 43, 46 adsorb and absorb liquid from the foodsurface. Adsorbed liquid is absorbed into the absorbent layer by flowingfrom the ridges 43, 46 to the valleys 44, 45 in the main body. Thevalleys 44, 45 are wider than the ridges 43, 46 and have a greatercapacity for holding liquid. In embodiments with polar liquids, forexample, solutions having strong intermolecular forces and/orintramolecular forces, such as, hydrogen bonding or van der Waalsinteractions, the ridges 43, 46 may provide a capillary force forabsorbing liquid from the food surface. The rates of adsorption andabsorption, the flow rate of liquid from the ridges to the valleys, andthe amount of capillary force necessary to absorb liquid from a foodsurface are dependent on the properties of the liquid, for example,viscosity and surface tension, and the absorbent layer, for example,porosity, ridge width, valley width, ridge height, and surface texturepattern.

In a preferred embodiment, the network of ridges 43, 46 and valleys 44,45 is continuous across at least one full surface of the compositematerial so that the adsorbent and absorbent properties provided bymaterial and surface texture of the absorbent layer pulls liquid acrossthe surface of the composite material. Absorbent layers having acontinuous network of adsorbent ridges 43, 46 extending out from anabsorbent main body wick liquid away from saturated areas and distributeit to unsaturated portions. By distributing liquid more evenlythroughout the absorbent layer, the surface texture prevents absorbedliquid from pooling on the surface of the composite material, therebyincreasing the layer's overall liquid carrying capacity and localabsorbance and absorbance capacity.

In one example, the ridges 43, 46 are in a loop like configuration withridges 43, 46 on the head of the loop being spaced further apart thanridges 43, 46 on the neck of the loop. The wide valleys 44, 45 at thehead of the loop are optimized for absorbing and holding liquid andwhile the high concentration of ridges 43, 46 at the narrow neck of theloop are optimized for adsorbing liquid. In other configurations, thesurface texture 48 may include a continuous network of ridges 43, 46laid out in straight or wavy line patterns and separated by valleys 44,45 consistently or irregularly spaced between the ridges 43, 46.Additionally, the ridges 43, 46 may also overlap in a square,rectangular, curved, or diamond pattern with valleys 44, 45 dispersedbetween the ridge pattern.

FIG. 5 is a cross sectional view of the composite material sheet of FIG.4, as taken along the dashed line 47. In this example, the compositematerial has three layers, a absorbent layer 52, a lamination layer 56,and a non-absorbent layer 57. The absorbent layer 52 includes a surfacetexture comprising a network of ridges and valleys 54. By attaching toridges on one side of the absorbent layer 52, the lamination layer 56seals the gap between the ridges and valleys on one side of theabsorbent layer 52. The seal created by the lamination layer 56 is shownby a series of semi-circular bubbles 55 that protrude into the gapbetween the valleys 54 and ridges on the top side of the absorbent layer56. The seal creates a network of pockets 50 between the top surface ofthe surface texture on the absorbent layer 52 and the bottom surface ofthe lamination layer 56. When the composite material contacts liquid,absorbed liquid is stored in the network of pockets 50 so that it doesnot drip or seep out of the absorbent layer 52. By compressing absorbedliquid into the network of pockets 50, the lamination layer 56horizontally displaces absorbed liquid across a wider surface area. Thehorizontal displacement created by the network of pockets holds liquidsin the composite material and prevents pooling. Additionally, bycompressing absorbed liquid in the network of pockets 50, the laminationlayer 56 creates a wicking effect that draws absorbed liquids across thesurface of the absorbent layer 52 away from saturated areas with fullpockets into unsaturated areas with empty pockets.

The lamination layer 56 joins the absorbent layer 52 to thenon-absorbent 57 layer. In this example, the lamination layer 56 alsoprovides a liquid barrier between the absorbent layer 52 and thenon-absorbent layer 57. The lamination layer 56 comprises a non-biotoxicwater based polymer emulsion coating with a flash point greater than400° F. The lamination layer 56 may be applied as a surface coating toat least one of the absorbent layer 52 or non-absorbent layer 57. In oneexample, the lamination layer 56 forms a liquid barrier between theabsorbent layer 52 and the non-absorbent layer 57. This liquid barriertraps liquid in the absorbent layer 52 and prevents absorbed liquidsfrom seeping through top layers of the composite material into thenon-absorbent layer 57. The lamination layer 56 allows the compositematerial to trap liquid in the absorbent layer 52 better thanconventional materials because it forms a first liquid barrier that isaugmented by a second liquid barrier, the non-absorbent layer 57. Thesequence of liquid barriers prevents absorbed liquid held in theabsorbent layer 52 from penetrating the composite material. Accordingly,materials in contact with the non-absorbent layer 57 are isolated fromabsorbed liquids held in the absorbent layer 52.

In this example, the lamination layer prevents all liquids from passingthrough the absorbent layer 52 to the non-absorbent layer 57. In otherembodiments, the lamination layer 56 may be configured to selectivelytrap certain types of liquid, for example, water based or oil basedsolutions, while allowing liquids with particular physical or chemicalproperties to pass through the absorbent layer.

Typical oil and grease and aqueous barrier coatings selected for thelamination layer 56, often comprise a higher polymer binder levelcompared to conventional print and binder coatings. Such coatingscontaminate recycling streams by rendering otherwise recyclablematerials not recyclable because complex, sticky polymer coatings aredifficult to breakdown in conventional acidic pulping processes. When ina strongly acidic environment, for example, in a solution with a pHlower than 2, the coatings tend to clump and form “stickies”, and otherparticles that are larger than the acceptable size for paper making fromrecycled materials.

Conventional coatings also often comprise petroleum based polymers. Suchcoatings contaminate composting streams because they do not readilydisintegrate in industrial scale composting processes. The high contentspecialty polymers, for example, a petroleum based polymer binder,present in these coatings makes meeting the >1% non-biodegradablecomposition requirement for the ASTM D6868-11 compostability standardextremely challenging.

In addition to the environmental concerns associated with conventionalcoatings, “blocking” is another common problem associated with coatedpaper materials. Blocking occurs when layers of coated paper materialstick together either in the real or after being rewound into rolls.Blocking in the reel is especially problematic when residual heat fromdryers dissipates slowly due to the large mass of the reel. Highertemperatures on the reel in turn can cause conventional coatings tostick or even melt as a result of thermal instability.

The lamination layer 56 described herein improves upon conventionalliquid barrier coatings because it is non-blocking, recyclable, andcompostable. In one example, the lamination layer 56 is made out ofnon-biotoxic materials that are safe for food contact applications andmeet the >99% biodegradable composition requirement of the ASTM D6868-11standard. Additionally, when placed between an absorbent layer 52 and anon-absorbent layer 57, the lamination layer 56 causes absorbed liquidsto wick across the surface of the absorbent layer 52. This wickingeffect is produced by applying an impermeable, semi-permeable, orolephillic lamination layer 56 to an absorbent layer 52 with an unevensurface texture. In this example, the absorbent layer 52 is a crepepaper with ridges, valleys, and other small structures extending outfrom—and protruding into—the main body of the absorbent layer.

The lamination layer 56 may further contain a binding agent thatincreases the lamination strength of the lamination layer 56. Increasingthe layer's lamination strength causes the laminated surface of thenon-absorbent layer to better adhere to the absorbent layer 52. In oneexample, applying the lamination layer 56 to the absorbent layer 52 andwaiting a period of one to five seconds before joining the non-absorbentlayer 57, improves the thermal degradation properties of the compositematerial. This method of combining the layers into a composite gives thelamination layer 56 time to set-in and partially fill the valleys on thesurface of the absorbent layer 52, thereby creating a uniform surface tojoin the non-absorbent layer 57. Pressing the non-absorbent layer 57 toa smooth surface of lamination layer 56 fortifies the bond between thelayers of the composite thereby increasing the flash point of thecomposite and minimizing paper curl. The lamination layer 56 may also beapplied as a print coating or can otherwise serve as a substrate for inkprinting.

To further enhance the composite material's ability to trap liquid, thenon-absorbent layer 57 forms a second liquid barrier. This additionalliquid barrier prevents any liquid passing through the lamination layer56 from penetrating the composite material. In one example, thenon-absorbent layer 57 is an oil and grease resistant paper materialthat repels fats, oil, and grease. In other examples, the non-absorbentlayer 57 is a water or liquid resistant paper material that repels atleast one of water, water based solutions, or any type of liquid.Additionally, the non-absorbent layer 57 may also comprise plastics andother synthetic materials, for example, petroleum-based polymermaterials including high density polyethylene (HDPE), low densitypolyethylene (LDPE), linear low density polyethylene (LLDPE), ultra lowdensity polyethylene (ULDPE), polyhydroxyalkanoate (PHA), polyglycolicacid (PGA), polyethylene terephthalate (PET), polypropylene (PP),polystyrene, and polyvinyl chloride (PVC).

In the configuration shown in FIG. 5, the exposed surface of theabsorbent layer is applied to a liquid surface. Liquid is adsorbed bythe network ridges extending from the surface of the absorbent layer 52and absorbed into the valleys comprising the main body of the absorbentlayer. Absorbed liquid is then stored in the network of pockets 50 andspread evenly throughout the network of ridges and valleys 54. Thelamination layer 56 seals one side of the absorbent layer 52 forming afirst liquid barrier on the top side of the absorbent layer 52. Theliquid barrier traps liquid in the absorbent layer and enhances thewicking effect of the absorbent layer by compressing liquid into thenetwork of pockets between the absorbent layer and lamination layer. Thenon-absorbent layer 57 attaches to the top of the lamination layer 56and provides a secondary liquid barrier to prevent any liquid thatpasses through the lamination layer 56 from penetrating the compositematerial.

Accordingly, the composite material makes food healthier and less messyby absorbing high calorie nutrients from the surface of greasy take outfood into the absorbent layer. A sequence of two liquid barriers, oneformed by the lamination layer and one formed by the non-absorbentlayer, further traps liquid in the absorbent layer to prevent absorbedliquid from penetrating the composite material. By trapping and holdingliquid absorbed from food surfaces, the composite material can preventliquid contaminants from reaching cookware, food packaging assemblies,sewer systems, and the hands of individuals eating food.

FIG. 1 is a pizza liner embodiment 10 comprising a composite materialhaving an absorbent layer 12 joined to a non-absorbent layer 14. Asillustrated, the composite 10 has a perimeter edge 16, which resultsfrom the joining of the absorbent layer 12, and the non-absorbent layer14. The composite 10 is dimensioned to cover a substantial portion of asurface of a pizza or other take out food and, accordingly, may beprovided in a number of different sizes to accommodate foods ofdifferent sizes.

The absorbent layer 12 may be made of any suitable material that iscapable of absorbing liquid in significant quantities. Such materialsinclude, but are not limited to, bi-component micro-fibers,biodegradable fibers, bleached fibers, cellulosic fibers, sulphitebleached fibers, and kraft bleached fibers. The material of theabsorbent layer 12 may include materials that are oleophilic, meaningthat they have an affinity for oils and grease but not water. Theabsorbent layer 12 is FDA approved for food contact applicationsincluding manufacturing, packaging, processing, preparing, treating,cooking, packing, transporting, or holding foods. The layer islow-linting, such that absorbent layer 12 does not leave lint on foodafter contact.

In one example, the absorbent layer 12 is a grade of crepe paper having94% biobased content and containing 5% water and up to 1% synthetic andnon-bio based materials. Further, the absorbent layer 12 is fluorinefree, non-biotoxic, and safe for food contact applications. The surfaceof the absorbent layer may also be textured to better absorb and trapliquid. In one example, the textured surface includes a continuousnetwork of ridges and valleys covering the entire front and back surfaceof the absorbent layer 12. The ridges are narrow elevated segmentsextending out from the surface of the absorbent layer 12 that adsorbliquid from food surfaces. The valleys are wider low lying areas betweenthe ridges that trap and hold absorbed liquid the main body of theabsorbent layer.

The paper material comprising the absorbent layer further meets the 99%biodegradable composition requirement of the ASTM D6868-11compostablility standard. The absorbent layer may comprise one or manysheets of 5 lbs to 70 lbs basis weight paper having a thickness of 1.0mil to 7.0 mils and a Sheffield porosity of 150 to 300 units. Theabsorbent layer further has an autoignition temperature greater than400° F. and a moisture percentage between 5.0% and 7.5%. The lowmoisture percentage minimizes paper curl and the autoignitiontemperature above 400° F. allows the material to be used in hightemperature cooking applications.

As shown in FIG. 2 and FIG. 5, the non-absorbent layer 14 may be made ofany suitable non-absorbent material that forms a liquid barrier. In thisexample, the non-absorbent layer 14 comprises a material that is notpermeable by oils or grease. Such materials include oil and greaseresistant papers (OGR), oleophobic fiber webs, polymeric films, andliquid barrier coatings. Advantageously, when the non-absorbent layer 14is made of a flexible OGR paper, the composite 10 may have a desirabledegree of malleability, such that the composite may be crumpled afteruse for convenient disposal without the user having to contact theoil-soaked absorbent layer 12.

In one example, the non-absorbent layer is an oil and grease resistant(OGR) material having a kit level between 3 and 8. The non-absorbentlayer is further fluorine free, non-biotoxic, and safe for food contactapplications. The non-absorbent layer has a flash point above 400° F. soit can be used in high temperature cooking applications. Thenon-absorbent layer 14 may be laminated to at least one surface of theabsorbent layer 12 to form a liquid barrier between the absorbent layerin contact with a food surface and the non-absorbent layer in contactwith an external surface, for example, a cooking surface, a customerholding food, or a recyclable material, such as, corrugated cardboard.The liquid barrier may repel water, polar liquids, oil, grease, organic,non-polar liquids, and mixtures thereof. The liquid barrier allows afirst portion of the composite material to absorb and trap liquid and asecond portion to prevent liquid from seeping through the first portion.

In a preferred example, the non-absorbent layer 14 is a compostable OGRpaper material having over 90% biobased content. The non-absorbent layermeets the 99% biodegradable composition requirement of the ASTM D6868-11compostability standard and contains no petroleum based polymers. Inanother example, the non-absorbent layer 14 is a liquid barrier coatedmaterial that repels OGR, water, and other liquids. The non-absorbentlayer 14 may include petroleum-based polymer materials including, highdensity polyethylene (HDPE), low density polyethylene (LDPE), linear lowdensity polyethylene (LLDPE), ultra low density polyethylene (ULDPE),polyhydroxyalkanoate (PHA), polyglycolic acid (PGA), polyethyleneterephthalate (PET), polypropylene (PP), polystyrene, and polyvinylchloride (PVC).

In one example, the absorbent layer 12 is a crepe paper comprisingcellulosic fibers and the non-absorbent layer 14 is an OGR paper. Morespecifically, the absorbent layer 12 is a crepe paper made of four tosix layers of cellulose wadding having a basis weight of 5 to 70 pounds.The material may be virgin material that is biodegradable andrecyclable. The sheets of wadding may be “pinned” together initially inan embossing type process to form a friction connection that creates aself-supporting sheet of absorbent material. An example of suchabsorbent material is the cellulose sheeting sold by PREGIS CORPORATIONunder the trademark CUSHION PACK.

The absorbent layer 12 is backed by the non-absorbent layer 14 andoptionally coated by a lamination layer. The non-absorbent layer 14 maybe an OGR paper or polymeric film, such as polyethylene, that is glued,attached by a lamination film, or otherwise affixed to the absorbentlayer to form the composite 10. In one embodiment, the non-absorbentlayer is laminated 10 to provide additional oil and grease resistance.

The composite material may also disintegrate naturally and bebiodegradable, non-toxic, and compostable under American Society forTesting and Materials (ASTM) or Biodegradable Products Institute (BPI)standards, for example, the ASTM D6400 testing criteria for plastic andthe ASTM D6868 testing criteria for coated paper products.

For use as an oil and grease absorbing food packaging material, thecomposite 10 is placed against a pizza or other food item from which oilor grease is to be absorbed with the absorbent layer 12 in contact withthe food item. The composite 10 may contact either an upper or lowersurface of the food, as desired, to extract oil or grease withoutadversely affecting the food. In the case of pizza, which is commonlyplaced in a box for transportation, this leads to at least the followingtwo potential positions of the composite 10 relative to the box.

FIG. 3 illustrates a pizza box assembly 30 that includes a pizza box 20and the pizza liner 10 shown in FIGS. 1 and 2. The pizza box 20 is astandard collapsible box used commonly in the industry, having an innercavity or receptacle 22 for holding the pizza such that the absorbentlayer 12 faces the inner receptacle 22. The composite 10 may be attachedto the interior top 24 of the box 20 by any suitable means, includingadhesives. In one aspect, the composite 10 may be removed after use andthe pizza box 20 may be recycled.

FIG. 6 illustrates an alternative pizza liner embodiment comprising thecomposite material of FIG. 4 and FIG. 5. The pizza liner includes anabsorbent layer 60 laminated or otherwise attached to a non-absorbentlayer 62. In this configuration, the pizza liner has an absorbent layer60 on top of a non-absorbent layer 62 so that the absorbent layer 60contacts the pizza and the non-absorbent layer 62 contacts the pizzabox. In this example, the pizza liner is rectangularly shaped anddimensioned to fit inside of a rectangular pizza box.

The pizza liner includes two side panels 63, 65 configured to hold thepizza liner in place and prevent the sides of the pizza from contactingthe sides of the pizza box. Further, the pizza liner includes two rearpanels 66, 68. The bottom rear panel 68 prevents the back surface of thepizza from contacting the hinge of the pizza box and holds the pizzaliner in place so it does not slide backward in the pizza box.Additionally, the bottom rear panel 68 props up the top rear panel 66making it more visible when the pizza box is open. When the pizza box isclosed, the top panel 66 prevents the top of the pizza from contactingthe top of the pizza box.

The top rear panel 66 further includes a printable surface for placingadvertisements, designs, and other printed writing or symbols. Byproviding a printable surface inside the pizza box, the top panel 66allows advertisements to be seen when the pizza box is open. Since mostconsumers of pizza eat pizza from an open box, the top panel 66 offersan improvement over the current state of the art for advertising on apizza box, attaching a paper flyer to the outer surface of the top ofthe pizza box. The base of the side panels 64, bottom rear panel 69, andtop rear panel 67 includes a scored edge allowing the pizza liner to beshipped flat and conform to the shape shown in FIG. 6 when placed insidea pizza box without additional folding. The scored edges 64, 67, and 69allow a pizza box assembly including a corrugated cardboard pizza boxand the pizza liner of FIG. 6 to be assembled in less than one second.

FIG. 7 is a plan view of the pizza liner embodiment of FIG. 6. The pizzaliner includes an absorbent layer 70 surrounded by two side panels 72,74, a top rear panel 76, and a bottom rear panel 78. The plan viewillustrates a front edge 71 cut into both front corners of the pizzaliner. The edges 71 are configured to accommodate rectangular pizzaboxes having the front corners folded in to accommodate a lid with atapered ends, as shown in FIG. 8. Scored edges 73, 75, 77, and 79 at thebase of each of panel are also visible in the plan view illustration.

FIG. 8 illustrates a pizza box assembly including the pizza linerexample of FIG. 6 and FIG. 7. In this example, when the box is closed,each side panel 83 is configured to come between its corresponding sidewall 80 on the top of the pizza box 88. Accordingly, the side panelsprevent the sides of the bottom and top of the pizza box from contactinga pizza disposed inside the box. The pizza liner is removable from thepizza box to allow the liner and the box to be disposed separately. Inuse, the pizza liner absorbs fats, grease, oil and other liquids on thesurface of the pizza and prevents the liquids from contacting the pizzabox. When the pizza is consumed or removed from the box, the liner maybe composed or otherwise disposed of and the pizza box, now without anyabsorbed grease or oils because of the protection provided by the liner,can be recycled or composted. Accordingly, the pizza liner makes foodhealthier by absorbing liquefied high calorie nutrients from a pizzasurface while also allowing the pizza box to be disposed in a moresustainable way by protecting the box from grease, oil, and othercontaminants.

FIG. 9 and FIG. 10 illustrate a third preferred pizza liner embodiment.Similar to the pizza liner of FIGS. 6-8, the liner includes an absorbentlayer 90 laminated or otherwise attached on top of a non-absorbent layer91, side panels 94, a bottom rear panel 98, a top rear panel 96, andscored edges at the base of each panel 97, 99, and 103. This examplefurther includes two front panels 92 and half circle tabs 95 on the topof the side panels 94. Similar to the side 94 and rear panels 96, 98,the front panels 92 prevent the front surface of the pizza fromcontacting the front portion of the pizza box. The front panels 92 alsohold the pizza liner in place so that it does not move forward whendisposed inside the pizza box. The half circle tabs 95 provide astructure to manipulate the side panels 94 when the pizza box is closed.

FIG. 11 illustrates a pizza box assembly including the pizza linerexample of FIG. 9 and FIG. 10. Similar to FIG. 8, the assembly includesa pizza box having a bottom portion 118 for disposing a pizza, a topportion 111 having a front portion with tapered ends 119, and sidepanels 110 positioned behind the liner's side panels 114. The assemblyfurther includes a pizza liner having side panels 114, a bottom rearpanel 116, a top rear panel 115 with a printable surface for placingadvertisements, designs, and other printed writing or symbols, frontpanels, and scored edges at the base of the front, side, and rearpanels.

The liner also includes a half circle tab 113 at the top of each sidepanel 114. In this example, when the box is closed the liner's sidepanels 113 may be re-positioned in front of the side walls 110 on thetop portion of the pizza box by inserting one or more fingers into apair of semi-circular holes on the side walls of the pizza box (notpictured) and moving the half circle tabs 113 on the liner's side panels114 forward. Displacing the liner's side panels 114 by inserting one ormore fingers to poke the half circle tabs 113 ensures the liner will notget crushed by the box top when the pizza box is closed. Accordingly,using the half circle tabs 113 to keep the liner intact and in position,enables the pizza liner to function as a device for preventing liquidfrom contacting the pizza box and for absorbing liquid from the pizzasurface.

The pizza box assemblies of FIG. 3, FIG. 8, and FIG. 11 may also includean additional liner comprising the composite material attached to theunderside of the top of the pizza box. The liners may be circular orrectangular shaped and dimensioned to cover the entire area of theinside of the pizza box or, alternatively, dimensioned to cover asubstantial portion of the pizza. In a preferred embodiment, a pizza boxliner comprising a composite material is disposed in the innerreceptacle of the pizza box at a location beneath the pizza. When thepizza in the box is cut or “scored” oil and grease from the pizza isefficiently wicked to the underside by the absorbent layer withoutdisturbing the upper surface of the pizza as can occur when a compositematerial is applied to the upper surface of the pizza. Therefore, anarrangement wherein the liner is disposed in the inner receptacle of thepizza box so that the absorbent layer contacts the bottom surface of thepizza operates advantageously in a surprisingly efficient manner toextract undesired oil and grease.

In use, when a pizza liner comprising the composite material ispositioned beneath the pizza, the pizza may be cut prior to or afterbeing placed on the composite. Due to the durable nature of thecomposite material, it is not normally severed when a rolling cutter isused on the pizza. Placement of a pizza liner comprising the compositematerial beneath the pizza enables excess oil and grease to passdownwardly to the composite for efficient absorption by the absorbentlayer. Absorbed oil and grease cannot pass beneath the composite,however, because the non-absorbent layer and lamination layer act asliquid barriers. The bottom of the pizza box therefore remains oil andgrease-free, enabling it to be recycled. Similarly, the front, rear, andside panels of the pizza liner protect the side, front, rear, and topwalls of the pizza box from oil, grease, and other contaminants.

As illustrated in FIGS. 3, 8, and 11, pizza liners comprising thecomposite material may be square or any other suitable shape to coverthe bottom of the pizza box. Particularly when the composite is placedbeneath a pizza or other food item, it may be desirable to cover theentire bottom of the container in which the food item is placed.Alternatively, pizza liners comprising the composite material placedbeneath a pizza may be circular and dimensioned to match the outline ofthe pizza.

In other instances, such as when pizza or other food items are consumedon the premises of a restaurant, the composite can still be used underthe food to absorb oil and grease. In any case, once the pizza isfinished, the composite may be folded inwardly onto itself withouttouching the grease-saturated absorbent layer by grasping thenon-absorbent layer.

As shown in FIG. 2, when food packaging assemblies comprising thecomposite material are used to blot a pizza or other food item fromabove, the non-absorbent layer 14 may have a flexible tab, string, orother physical feature 32 enabling the user to lift the compositematerial away from the food without touching the saturated absorbentlayer 12. The weight of the absorbed oil and grease then causes thecomposite material 10 to hang downwardly with the grease-impermeablenon-absorbent layer 14 on the outside, facilitating disposal of the foodpackaging assembly without getting oil or grease on the user's hands.

When the non-absorbent layer 14 is metallic, a thick paper, or somecombination, the composite 10 also serves an additional purpose ofretaining heat within the pizza by reflection in either an up or downdirection, depending on the position of the composite.

In another form, separate liners comprising the composite material 10may be provided above and below a pizza with the absorbent layer 12facing and in contact with the surfaces of the pizza to absorb oil andgrease from both the top and the bottom of the pizza. Alternatively, thetop and bottom layers of the composite material 10 may comprise a singlesheet of the composite that extends underneath the pizza and is foldedover to also engage the top of the pizza to absorb oil and grease fromthe top and bottom of the pizza simultaneously.

The foldable nature of the composite enables it to be packaged in acompact and inexpensive package, which may be in the form of a sealedplastic, paper, or foil-backed pouch, as illustrated in FIGS. 12-17. Inthis form, the composite is suitable for distribution with a take-outpizza or other food item for convenient use by the consumer inextracting oil and grease from the food item. In situations where a foodpackaging assembly comprising a composite material is used to distributepizza, popcorn, burgers, or other take out foods, a stand alone sheet ornapkin comprising the composite material may also be provided for manualuse by the consumer to further reduce the quantity of oil and/or greaseconsumed.

FIGS. 12-14 illustrate a bag assembly comprising a composite material.In one example the bag assembly is used to distribute take out food.FIG. 12 illustrates an empty bag assembly having an inner surface 121comprising an absorbent layer. The inner surface 121 is configured toabsorb liquid, for example, fats, grease, oil, water, or somecombination from the surface of food disposed in the bag. The bagassembly further includes an outer surface 120. In one example, theouter surface 120 comprises an absorbent layer for absorbing fats,grease, oil, water and other liquids from hands used to pick up and eatfood disposed in the bag assembly. In this example, the bag assemblyincludes a liquid barrier 122 positioned between the inner surface 121and the outer surface 120. The liquid barrier 122 traps liquid absorbedfrom the food surface in the absorbent layer of the inner surface 121 toprevent liquid absorbed by the inner surface 121 from reaching the outersurface 120. Similarly, the liquid barrier 122 traps liquid absorbedfrom hands used to pick up and eat the food in the outer surface 120 toprevent liquid absorbed by the outer surface 120 from reaching the innersurface 121. In this example, the liquid barrier 122 comprises alamination layer, a non-absorbent layer, or some combination.

The composite material described herein may be converted into bagassemblies, such as, square bottom bags and pinch bottom bags, as wellas other food packaging assembles, for example, tray liners, sandwichand burger wrappers, basket liners, French fry and hash brown pouches,napkins, bowls, plates, trays, and boxes. The bag assembly of FIG. 12 isa square bottom bag further comprising scored edges running down themiddle of the side portions of the bag assembly 123 and out from the midpoint of the bottom of the bag toward the outer surfaces 124. The scorededges 123, 124 allow bag assemblies to be shipped flat and rapidlyunfolded for use. FIG. 13 illustrates the bag assembly with popcorn 130disposed inside the inner receptacle of the bag. Popcorn is one of manytake out foods that can be distributed in the bag assembly containing acomposite material. Other take out food suitable for distribution inthis bag assembly include, for example, pizza, hamburgers, tater totsand French fries, corn dogs, doughnuts, and biscuits.

FIG. 14 is a top plan view of the bag assembly 140 that illustratespopcorn 144 and other take out food items disposed in the bag makedirect contact with the absorbent layer 143 in the inner surface.Additionally, this view displays the separate components of this exampleincluding the inner absorbent layer 143, the middle liquid barrier 142,and the outer absorbent layer 141.

FIGS. 15-17 illustrate a baking sheet 150 comprising a compositematerial. In use, the baking sheet 150 may be placed in a baking pan 151and used to cook food at high temperatures. In this example of FIG. 15,bacon 152 is placed on a baking sheet 150 disposed in a baking pan 151and cooked at 450° F. FIG. 16 illustrates the baking sheet after thebacon is cooked and removed from the baking sheet. Dark colored areas160, 165 on the top surface 162 of the baking sheet show fat, oil,grease, water, and other liquids that are absorbed into the baking sheetduring and after cooking. Absorbed liquids are trapped in the absorbentlayer so that the bottom surface 161 of the baking sheet 150 and thesurfaces of the pan 164 covered by the baking sheet are not contacted byfats, oils, grease, water, and other liquids absorbed from the food. Thebaking sheet 150 is further removable from the baking pan so that it canbe separately disposed. By preventing liquids excreted by the foodduring and after cooking from contaminating the baking pan 151, usingthe baking sheet comprising a composite material as a baking pan linerallows the baking pan 151 to be reused without washing. Using the bakingsheet to absorb fats, oils, grease, sodium, and other high calorienutrients from the surface of the food further makes food healthier byreducing consumption of high calorie nutrients contained in take outfoods.

The baking sheet may be dimensioned to be disposed in a rectangular,square, or circular baking pan. Alternatively, it may be distributed ona roll so it can be cut to size. In one example, the baking sheet 167has scored edges 168 around the outer surface 166 of the sheet. Scoringallows the outer edge 166 of the sheet 167 to be folded up to cover theside surfaces of the baking pan. In a preferred example, the outer edgeof the sheet 166 has a width of a quarter inch beyond the scored edge168. In this example, grease would have to travel a quarter inch abovethe bottom surface of the baking sheet 167 to contact the side surfacesor the rim of the baking pan 151. In other examples, the outer edge 166of the baking sheet 167 is greater than a quarter inch. In theseexamples, the outer edge 166 may fold over the entire side surfacesand/or rim of the baking pan 151. In a preferred example, the outer edge166 is wide enough to cover all surfaces of the baking pan 151. In thisexample, none of the surface area of the baking pan 151 is uncovered andopen for contamination by liquid excreted from food during cooking.

In use, a baking sheet 161, 162 comprising the composite material isdisposed in a baking pan 151. The absorbent layer is positioned facingupward so that it can directly contact the bottom surface of the food.One or more liquid barriers, for example, a lamination layer ornon-absorbent layer, are attached to the absorbent layer so that theliquid barriers are positioned between the absorbent layer and thesurface of the baking pan 163, 164. Food is then cooked on the surfacebaking sheet so that fats, grease, oils, water, and other liquidsexcreted from the food during cooking are absorbed by the baking sheet.Once absorbed, liquid is then trapped in the absorbent layer by one ormore liquid barriers. These liquid barriers prevent absorbed liquid fromcontaminating the baking pan surfaces 163, 164.

An example baking sheet comprising the composite material illustrated inFIG. 5, includes a lamination layer 56 that forms the first liquidbarrier and is coated directly on the back surface of the absorbentlayer 52. A non-absorbent layer 57 forms the second liquid barrier andis attached to the rear surface of the lamination layer 56. In oneexample, the non-absorbent layer 57 is an OGR paper material. In otherexamples, the non-absorbent layer 57 comprises a synthetic polymer basedliquid barrier material, for example, high density polyethylene (HDPE),low density polyethylene (LDPE), linear low density polyethylene(LLDPE), ultra low density polyethylene (ULDPE), polyhydroxyalkanoate(PHA), polyglycolic acid (PGA), polyethylene terephthalate (PET),polypropylene (PP), polystyrene, and polyvinyl chloride

Characterization

Samples of the embodiments described herein were tested forcompostability and absorbance. The chemical composition of the sampleembodiments was also discerned to evaluate the material's safety forfood contact applications. Compostability tests were performed accordingto the American Society for Testing and Material (ASTM) Internationaltest for standard specification for labeling of end items thatincorporate plastics and polymers as coatings or additives with paperand other substrates designed to be aerobically composted in municipalor industrial facilities or the ASTM 6868. Tests were performed underlaboratory conditions at the University of Wisconsin-Stevens PointInstitute for Sustainable Technology in Stevens Point, Wisconsin.

The ASTM 6868 is a set of testing criteria used by the BiodegradableProducts Institute (BPI) to certify compostable materials and productssuch as food packaging. BPI relies on the ASTM D6400 test for plasticand the ASTM 6868 test for coated paper products or paper materialspolymer binding agents. To pass ASTM tests and become part of BPI'scertified compostable program, a product must: i) disintegrate quicklyleaving no visible residue that has to be screened out, ii) biodegradefully or convert rapidly to carbon dioxide water and biomass, iii)result in compost that supports plant growth, and iv) not introduce highlevels of regulated materials into the soil.

The ability of samples to absorb fat, calories, cholesterol, fattyacids, and sodium from the surface of cooked take-out pizzas was testedusing pizzas obtained from PIZZA HUT, DOMINO's, PAPA JOHN's, LITTLECAESARS, and SABARRO. Pizzas contacting samples included thin crustpizzas, thick crust pizzas, meat lovers pizzas, and veggie pizzas.Testing was performed under laboratory conditions by COVANCELABORATORIES, INC. of Madison, Wis.

Compostability

Disintegration and biodegradation methodology for this experiment wasbased on a modified version of the ASTM method for compostability testedwithout humidified aeration and carbon dioxide capture (ASTM D5338).Industrial composition conditions were simulated in a laboratoryincubator set to 58° C.±20 for 7 weeks in the Wisconsin Institute forSustainable Technology Compostability Laboratory at the University ofWisconsin Stevens Point College of Natural Resources. The compostingvessels were 2-liter KIMAX glass bottles closed at the top by a rubberstopper fitted with a hole running through the center. An air-tightrubber sleeve was fitted around the threaded mouth of the bottles toavoid sticky glass on rubber contacts between the bottle and stopper. Aplastic tube was inserted through the stopper hole into the glass bottleto limit moisture loss while providing for controlled gas exchangeduring composting.

There were two treatments tested in this example: a paper compositematerial and untreated cellulose paper. A negative blank of maturecompost was also tested as a control. The untreated cellulose paper andpaper composite material were added to compost in a 6:1 or 16% paper todry compost ratio. Each treatment and the control were replicated seventimes with each vessel comprising a complete, distinct sampling unit.There were twenty one vessels at the beginning of the experiment, withthree sampling units removed at the end of weeks 1, 2, 3, 4, 5, 6, and7. The vessels were placed in the incubator in a complete randomizeddesign.

The compost in this experience is municipal, deciduous left compost(mature 2-4 months) sourced from Hsu's Compost and Soils in Wausau, Wis.Hsu's leaf compost is certified through the United States CompostingCouncil (USCC) according to the Seal of Testing Assurance (STA) program.The compost was composed of tree leaves from municipal collection in theWausau and Appleton, Wis. areas. Each 2-liter vessel required required615 g of as-received (moist) compost. The compost was sieved using an 8mm sieve to remove large debris, which was then discarded. Maturecompost was used based upon the D5338 method for coated paperdisintegration.

The paper composite material was prepared using an absorbent crepe paperand a non-perfluorooctanoic acid (PFOA), non-perfluorooctane sulfuicacid (PFOO), non-perfluorinated carboxyilic acid (PFCA), andnon-perchlorate OGR paper from Expera Specialty Solutions in Moisinee,Wis. The papers laminated together using a non-hazardous water basedpolymer emulsion laminate supplied from—and applied by—ProlaminaFlexible Packaging Solutions, a division of Proampac, in Neenah, Wis.The untreated cellulose paper was also obtained from Expera SpecialtySolutions.

The paper treatments were incorporated into the compost by cutting thepaper and paper composite material, by hand, into 2 cm×2 cm squaresaccording to the ASTM D5338. The squares were then weighted in a beakerto discern the number of squares added to each vessel to achieve thedesired 6:1 (615 g: 98.4 g) compost to paper ratio. Compost (615 g) wasweighed into each of the twenty one vessels and the pre-weighted paperwas added. Distilled water was added to bring the entire compost andpaper matrix up to 60%±2% moisture content. Between 101 mL and 110 mL ofdistilled water was added to each vessel and moisture content of theinitial compost was determined gravimetrically by weighing samples fromeach vessel and drying for 48 hours in a 105° C. oven. The compost,paper, and water were mixed thoroughly using 2-pronged forks until auniform matrix was produced. Each vessel was labeled with the week ofits removal, the treatment, and the paper addition.

Each week during the 7 week active composting period, the compostvessels were removed from the incubator and weighed. Moisture wasmaintained between 50% and 60% throughout the 7 week trial. Moistureadditions were based on individual jar weight loss and visualobservations of compost and paper structure. Moisture additions weremade by adding distilled water to individual vessels based on weight andadditional water was mixed in using a flat soil knife. Hand mixing wasnecessary to promote aeration and consistent moisture distributionthroughout the compost matrix. Mixing occurred twice a week, once withmoisture additions and once without.

During final sampling of vessels removed at various weeks, the paper wasseparated from the compost using a series of 3 brass sieves (8 mm, 4 mm,and 2 mm) and picked from the compost using tweezers. Paper too large topass through the 2 mm sieve was weighted (including residual compost).Paper was further processed by washing with de-ionized water over a 2 mmsieve. With much of the residual compost removed, the paper was dried inan oven at 60° C. for 6 hours. Final paper mass was recorded once dry.Paper and compost, per vessel, from removed vessels, were storedseparately in quart sized ZIPLOC freezer bags. The remaining vesselswere returned to the incubator in a re-randomized order. Samples fromremoved vessels were frozen and stored in a 0° C. walk-in freezer.

Results of the compostability testing are shown below in Table 1.

TABLE 1 Start Final % Breakdown Material Weight Weight TheoreticalCarbon Composite Material 98.4 g 19.1 g 80.6 Untreated Cellulose Paper98.4 g 19.9 g 79.8

After 5 weeks, the composite paper material and the untreated cellulosepaper were both ahead of the 90% breakdown benchmark (72% breakdown).After 12 weeks, the % breakdown theoretical carbon of the compositematerial was over the ASTM D6868 90% benchmark for biodegradation andmore than 90% of the original material was lost to disintegration.

FIG. 6 illustrates the % breakdown of the composite material and theuntreated cellulose paper over the first 5 weeks of the compostabilitytesting. As shown in the figure, after 10 days, the composite materialwas in-line with or exceeded the 90% breakdown benchmark. Furthermore,after 35 days, the composite material out performed both the 90%benchmark (by 8.6%) and the untreated cellulose paper (0.8%) inbiodegradation and disintegration.

Nutrient Absorbance

The composite material was evaluated for its ability to absorb excessnutrients from the surface of greasy takeout foods. Pads made from thecomposite material were placed in contact with pizzas obtained from fivepopular take out pizza chains-PIZZA HUT, DOMINO's, PAPA JOHN's, LITTLECAESARS, and SABARRO in Madison, Wis. Pads weight ranged from 11.8 g to7.3 g so that pads of various sizes could be evaluated for there abilityto absorb nutrients from different types of take out pizza. Thin crust,thick crust, “meat lovers”, and veggie style pizzas were tested.Absorbance experiments were performed by Covance Laboratories, Inc. ofMadison, Wis. Samples very prepared in the field in a mobile laboratoryand nutrient extraction was performed under laboratory conditions usingthe Soxhlet extraction method.

Samples were prepared by applying pads to the top and bottom surfaces ofthe pizzas. Once in contact with the pizza, the composite materialabsorbed nutrients from the pizza surface into the pads. Soaked padswere stored on ice and transported to Covance Laboratories for nutrientextraction and absorbance analysis.

Nutrients were absorbed form the pizzas using this method: i) weighcomposite paper material pad before use, ii) obtain a take out pizza incorrugated cardboard pizza box from a take out restaurant, iii) within 5minutes of purchasing the pizza, insert the pad underneath the bottomsurface of the pizza so that the pad is between the pizza surface andthe cardboard box, iv) close the pizza box and weight 30 minutes, v)apply a second pad to the top surface of the pizza by pressing downlightly to assure contact between the pizza and the composite material,vi) remove both pads after 2 minutes of contact by the second pad, vii)remove any loose toppings of pizza material from the pads, and viii)weigh each pad separately immediately after use.

Nutrients were extracted from prepared samples using the Soxhletextraction method. The extraction was conducted under laboratoryconditions using the extraction method described in Official Methods ofAnalysis of AOAC INTERNATIONAL, Method 960.39 and 948.22 published byAOAC INTERNATIONAL of Gaithersburg, Md. Excess nutrients were extractedfrom pads made from paper composite material by: i) obtain pads appliedto take food in the field, ii) weigh pads into a cellulose thimblecontaining sea sand and dried to remove excess moisture, iii) extractnutrients from pads using penetne as a solvent for 5 hours, iv)evaporate pentene from the extract, v) dry and weigh the extract foranalysis.

Upon extraction, the composition of extracted nutrients was determinedby Inductively coupled plasma atomic emission spectroscopy (ICP-AES).This technique produces an inductively coupled plasma to excite atomsinto emitting a electromagnetic radiation response that ischaracteristic of a particular element or combination of elements.Measured sodium and fat content of the extract absorbed by the compositepaper material pads was then used to calculate the fat and sodiumcontent of the nutrients absorbed by the pad from the pizzas. Thepercent of the pizza's total sodium and fat content absorbed by thecomposite material was determined using the nutrient content analysis toprovide an estimate for the paper composite materials ability to removefat and sodium from take out foods.

Results of the fat absorance analysis including are displayed below inTable 2.

TABLE 2 Absorbed Absorbed Absorbed % Fat Sample Nutrients Fat CaloriesReduction Pad 1 11.80 g  10.49 g  94.4 Cal 9.5% Pad 2 9.60 g 9.09 g 81.8Cal 8.8% Pad 3 9.10 g 8.12 g 73.1 Cal 7.4% Pad 4 10.60 g  7.97 g 71.8Cal 6.1% Pad 5 11.10 g  9.42 g 84.8 Cal 8.1% Pad 6 8.60 g 6.88 g 61.9Cal 5.6% Pad 7 8.60 g 6.48 g 58.3 Cal 5.0% Pad 8 9.60 g 8.70 g 78.3 Cal8.0% Pad 9 7.30 g 6.77 g 60.9 Cal 6.4% Pad 10 8.90 g 8.29 g 74.6 Cal7.9% Average 9.52 g 8.22 g 69.2 Cal 7.3%

Fat in this analysis includes saturated fatty acids, monounsaturatedfatty acids, polyunsaturated fatty acids, and trans fatty acids. Thefatty acids measured in this analysis include, Butyric Acid, CaproicAcid, Caprylic Acid, Capic Acid, Lauric Acid, Myristic Acid, MyristoleicAcid, Pentadecanoic Acid, Pentadecenoic Acid, Palmitic Acid,Heptadecanoic Acid, Heptadecenoic Acid, Stearic Acid, Oleic Acid,Linoleic Acid, Arachidic Acid, Gamma Linolenic Acid, Elcosadienoic Acid,Behenic Acid, Erucic Acid, Elcosatrienoic Acid, Arachidonic Acid,Arachidonic Acid, and Lignoceric Acid. On average, 86.5% of all AbsorbedNutrients were Fat leaving only 130.5% for sodium, cholesterol, an othernutrients. % Total Fat was calculated assuming a pizza with 98 g fat perserving.

Results of the sodium absorbance analysis are shown below in Table 3.

TABLE 3 Absorbed Absorbed % Sodium % Daily Sample Nutrients % SodiumSodium Reduction Value Pad 11 10.2 g 0.56% 57.6 mg 1.0% 1.6% Pad 12 15.6g 0.10% 15.3 mg 0.27% 0.64% Pad 13 34.6 g 0.07% 25.5 mg 0.45% 1.06%Average 21.0 g 0.24% 32.8 mg 0.57% 1.1%

Sodium measured in this analysis includes chloride and sodium chloridesalt. % Sodium Reduction was based on a total sodium value of 5,610 mgper serving and % Daily Value was calculated using a 3,400 mg sodiumdaily value.

Thermal Insulation

The composite material was evaluated for its ability to thermallyinsulate food. Specifically, the material's tendency to reduce heat lossfrom cooked food while inside conventional food packaging was evaluatedrelative to a control sample. Temperature data was gathered on largepizzas obtained from five popular take out pizza chains-PIZZA HUT,DOMINO's, PAPA JOHN's, LITTLE CAESARS, and SABARRO in Madison, Wis. Inorder to isolate the thermal insulation character of the compositematerial, pizzas were kept in corrugated cardboard boxes throughout theexperiment for both the control samples and the samples containing thecomposite material. Thermal insulation experiments were performed byCOVANCE LABORATORIES, INC. of Madison, Wis. Samples were prepared andtemperature data was collected in the field in a mobile laboratory usingan infrared thermometer.

Samples containing the composite material were prepared by placing afirst pad composed of the composite paper material under the pizza and asecond pad over the top surface of the pizza 10 minutes after obtainingthe pizza. Temperature measurements were made for the control samples 5minutes after receiving the pizza and 30 minutes after receiving thepizza. The total time for the control experiment was 25 minutes. For thecomposite material samples, temperature measurements were made 5 minutesafter obtaining the pizza (5 minutes before placing the sheet) and 30minutes after applying the pads to the pizza. The total time for thecomposite material experiment was 35 minutes. To obtain the thermalinsulation property, the initial temperature of the pizza was subtractedfrom the final temperature of the pizza. Each experiment was repeatedseven times to collect data across multiple trials.

Results of the thermal insulation experiments for the control samplesare displayed below in Table 4.

TABLE 4 Sample Initial Temperature Final Temperature Temp. DifferenceControl 1 58.9° C. 47.9° C. 11.0° C. Control 2 69.0° C. 58.8° C. 10.2°C. Control 3 69.9° C. 61.7° C.  8.2° C. Control 4 75.6° C. 63.2° C.12.4° C. Control 5 69.3° C. 59.2° C. 10.1° C. Control 6 70.4° C. 54.2°C. 16.2° C. Control 7 69.5° C. 46.2° C. 23.3° C. Average 68.9° C. 55.9°C. 13.1° C.

Results of the thermal insulation experiment for the composite materialsamples are displayed below in Table 5

TABLE 5 Sample Initial Temperature Final Temperature Temp. DifferencePad 1 61.6° C. 54.4° C.  7.2° C. Pad 2 59.0° C. 54.4° C.  4.6° C. Pad 366.1° C. 59.5° C.  6.6° C. Pad 4 64.4° C. 53.1° C. 11.3° C. Pad 5 67.2°C. 53.8° C. 13.4° C. Pad 6 66.1° C. 54.4° C. 11.7° C. Pad 7 66.4° C.47.3° C. 19.1° C. Average 64.4° C. 53.8° C. 10.6° C.

The preceding discussion merely illustrates the principles of thepresent pizza-blotting composites and pizza box assemblies containingsuch pizza-blotting composites. It will thus be appreciated that thoseskilled in the art may be able to devise various arrangements, which,although not explicitly described or shown herein, embody the principlesof the inventions and are included within their spirit and scope.Furthermore, all examples and conditional language recited herein areprincipally and expressly intended to be for educational purposes and toaid the reader in understanding the principles of the invention and theconcepts contributed by the inventor to furthering the art and are to beconstrued as being without limitation to such specifically recitedexamples and conditions.

Moreover, all statements herein reciting principles, aspects, andembodiments of the invention, as well as specific examples thereof, areintended to encompass both structural and functional equivalentsthereof. Additionally, it is intended that such equivalents include bothcurrently known equivalents and equivalents developed in the future,i.e., any elements developed that perform the same function, regardlessof structure. Terms such as “upper”, “top”, and “lower” are intendedonly to aid in the reader's understanding of the drawings and are not tobe construed as limiting the invention being described to any particularorientation or configuration.

This description of the exemplary embodiments is intended to be read inconnection with the figures of the accompanying drawings, which are tobe considered part of the entire description of the invention. Theforegoing description provides a teaching of the subject matter of theappended claims, including the best mode known at the time of filing,but is in no way intended to preclude foreseeable variationscontemplated by those of skill in the art.

We claim:
 1. A composite material comprising: an absorbent layer havinga surface texture configured to absorb liquids from a food surface, thesurface texture including a system of ridges and valleys; and anon-absorbent layer joined to at least one side of the absorbent layer,the non-absorbent layer including an oil and grease resistant materialthat forms a liquid barrier between the absorbent layer and thenon-absorbent layer.
 2. The composite material of claim 1, wherein thesystem of ridges and valleys includes valleys positioned between ridges.3. The composite material of claim 2, wherein the valleys areencompassed in a main body portion of the absorbent layer.
 4. Thecomposite material of claim 3, wherein the ridges comprise a network ofelevated line segments extended out from the main body portion.
 5. Thecomposite material of claim 4, wherein the ridges are dimensioned andpositioned on the absorbent layer to facilitate absorption of liquidinto the main body portion of the absorbent layer by adsorbing liquidfrom a food surface when placed in contact with a food surface.
 6. Thecomposite material of claim 5, wherein the valleys are dimensioned andpositioned on the absorbent layer to receive liquid adsorbed andabsorbed by the ridges and trap said liquid in the absorbent layer toprevent liquid from flowing out of the absorbent layer.
 7. The compositematerial of claim 6, wherein the valleys further trap liquid in theabsorbent layer to prevent liquid from passing through the absorbentlayer and reaching other layers in the composite material.
 8. Acomposite material comprising: a absorbent layer having a surfacetexture configured to adsorb and absorb liquids from a food surface; anon-absorbent layer laminated to at least one surface of the absorbentlayer, the non-absorbent layer including an oil and grease resistantmaterial that forms a first liquid barrier between the absorbent layerand the non-absorbent layer; and a lamination layer applied to at leastone surface of the absorbent layer, the lamination layer joining theabsorbent layer to the non-absorbent layer to create a second liquidbarrier between the absorbent layer and the non-absorbent layer.
 9. Thecomposite material of claim 8, wherein the lamination layer is appliedto the absorbent layer as a surface coating that seals gaps left on thesurface of the absorbent layer by the surface texture.
 10. The compositematerial of claim 9, further comprising a network of pockets between thetop surface of the surface texture and the bottom surface of thelamination layer, wherein the network of pockets is created by the sealover the surface texture of the absorbent layer from the laminationlayer.
 11. The composite material of claim 10, wherein liquid absorbedinto the main body of the absorbent layer is compressed into the networkof pockets.
 12. The composite material of claim 11, wherein compressingliquid into the network of pockets horizontally displaces absorbedliquid across a wider surface area, said horizontal displacement createsa wicking effect that draws absorbed liquid away from saturated areas ofthe absorbent layer and distributes liquid to unsaturated areas of theabsorbent layer.
 13. The composite material of claim 11, wherein thehorizontal displacement of liquid created compressing absorbed liquidinto the network of pockets holds liquid in the composite material andprevents liquid from pooling on the absorbent layer.
 14. The compositematerial of claim 9, wherein, after application, the lamination layer isleft sitting on the absorbent layer for a period of time before thenon-absorbent layer is stacked on top of the laminated absorbent layer,giving the lamination layer time to set-in before stacking thenon-absorbent layer creates a uniform surface on the absorbent layer toreceive the non-absorbent layer, the uniform surface for receivingadditional layers fortifies the bond between layers in the compositematerial, thereby increasing the lamination strength and flash point ofthe composite material.
 15. The composite material of claim 14, whereinthe uniform surface is generated by giving the lamination layer one tofive seconds to set in on top of the absorbent layer.
 16. The compositematerial of claim 9, wherein the combination of the first liquid barrierincluded in the non-absorbent layer and the second liquid barrierincluded in the lamination layer prevents absorbed liquid from passingthrough the composite material.
 17. The composite material of claim 16,wherein the liquid barriers repel liquid contacting the compositematerial to protect a surface covered by the composite material fromcontaminants in the liquid.
 18. The composite material of claim 17,wherein the surface covered by the composite material includes at leastone of food packaging assembly, a piece of cookware, or a hand of aperson.
 19. A composite material comprising: a absorbent layer having amain body configured to trap liquids and a surface texture configured toadsorb and absorb liquids from a food surface, the surface texturecomprising: a system of ridges extending out from the main body, theridges spread across at least one surface of the absorbent layer tocreate a network of narrow, elevated segments that contact liquid on afood surface, the elevated segments provide a capillary force forabsorbing liquids from a food surface; and a system of valleys spacedbetween the ridges and included in the main body of the absorbent layer,the valleys receive absorbed liquid from the ridges and store theabsorbed liquid in the main body; a non-absorbent layer laminated to atleast one surface of the absorbent layer via a lamination layer, thenon-absorbent layer having a liquid resistant material that forms afirst liquid barrier between the absorbent layer and the non-absorbentlayer, the first liquid barrier positioned between the absorbent layerand an external surface to prevent absorbed liquid trapped in theabsorbent layer from seeping through non-absorbent layer and contactingthe external surface; and a lamination layer applied to at least onesurface of the absorbent layer, the lamination layer joins the absorbentlayer to the non-absorbent layer to create a second liquid barrierbetween the absorbent layer and the non-absorbent layer, the secondliquid barrier compresses absorbed liquid into the space between the topsurface of the ridges and the bottom surface of the valleys to preventpooling of absorbed liquid in the absorbent layer and promote more evenliquid absorption in the absorbent layer by wicking absorbed liquidacross the surface of the absorbent layer.
 20. The composite material ofclaim 19, wherein the system of ridges and valleys is continuous acrossthe entire surface of the composite material, the system of ridges andvalleys is continuous to increase the overall liquid carrying capacityof the absorbent layer and increase the local absorbance and absorbancecapacity of ridges in contact with- or in close proximity to liquid.